Five-axis CNC tool grinding research report

【Abstract】 This paper discusses the technical characteristics, structural forms, key technologies and important supporting parts of CNC machine tools and CNC tools, five-axis CNC tool grinding, and introduces the typical five-axis CNC tool grinding machine. Type, proposed to accelerate the development of domestic five-axis CNC tool grinding.

CNC machine tools, CNC tools, and CNC measuring instruments are called the three pillars of modern machinery manufacturing. CNC machine tools are the working machine, CNC tools and CNC measuring instruments are referred to as CNC machining of teeth and eyes. The technological advances of the three pillars drive the continuous upgrading of processing precision, efficiency and manufacturing methods in modern manufacturing.
The industry is accustomed to calling high-precision tools with high precision, high efficiency, high reliability and specialization as CNC tools. Since the material of the numerical control tool generally adopts high-performance high-speed steel, hard alloy and super-hard material, the grinding becomes the mainstream processing technology of the numerical control tool, so that the numerical control tool grinding machine as the working tool of the numerical control tool plays a key role. The variety of CNC tools determines the variety of CNC tool grinding machines, such as CNC drill sharpening machine, CNC milling sharpening machine, CNC broach sharpening machine, CNC hob sharpening machine, CNC reamer sharpening machine, CNC tap grinding machine, The CNC circular saw blade sharpening machine plays a unique role in the processing of the corresponding CNC tools. In the past two decades, the advancement of multi-axis linkage and other numerical control technologies has promoted the rapid development of five-axis CNC tool grinding. Because this model can sharpen various complex-shaped CNC tools, it has versatility and versatility, five-axis CNC. Tool grinding has become a shining star in the CNC tool grinding machine family.

First, the market demand is broad

In today's world, China has become the world's largest equipment manufacturing country. According to reports, in 2013, the output value of China's equipment manufacturing industry exceeded 20 trillion yuan, 2.2 times that of 2008, accounting for about one-third of the global equipment manufacturing output ratio, ranking first in the world. Among them, the output of power generation equipment is 120 million kilowatts, accounting for 60% of the world; the completion of shipbuilding is 45.34 million deadweight tons, accounting for 41% of the world; the output of automobiles is 22.12 million, accounting for 25% of the world; the output of machine tools is 960,000, accounting for 38% of the world. . In addition, the annual output of washing machines, refrigerators, motorcycles, air conditioners, televisions, mobile phones, etc. are among the highest in the world. The machine tool is the working machine of the equipment manufacturing industry. From 2002 to 2013, China has become the world's largest consumer of machine tools for 12 consecutive years. The consumption of machine tools accounts for 40%-45% of the total global machine tool consumption. According to relevant statistics, Figure 2 shows the consumption of machine tools in China from 2005 to 2013.

It goes without saying that China is also the world's largest consumer of cutting tools. It is reported that in 2013, China's tool consumption was 33 billion yuan, of which imported tool was 11.5 billion yuan; the proportion of domestic high-end tools (CNC tools) has risen from 15% in the early 11th Five-Year Plan to 25%, showing a good trend. However, the development potential is still huge. According to the relevant information of the tool industry, Figures 3 and 4 show the consumption scale and tool import scale of China's tool market in 2005-2013.
The rapid increase in the demand for CNC tooling in China has given birth to the huge market potential of CNC tool grinding machines. At present, the high-end CNC tool grinding machine mainly relies on imports. It is reported that the number of 4-5 axis CNC tool grinding machines imported by major tool manufacturing enterprises in China has reached more than 100 sets, and some medium-sized tool manufacturers have also imported dozens of such machine tools. For example, in 2012, a tool manufacturing backbone enterprise imported 90 sets of 4-5 axis CNC tool grinding machines at a time, with a sink of 44.03 million US dollars. In addition to tool manufacturing companies, many mechanical manufacturing companies also account for a large proportion of imported 4-5-axis CNC tool grinding machines due to the need for tool grinding and manufacturing. According to customs statistics, Figure 5 shows the import value of CNC tool grinding machines in China from 2005 to 2013 (Note: The main type of imported CNC tool grinding machines is 4-5 axis CNC tool grinding).

Technical characteristics of two- and five-axis CNC tool grinding

The modern five-axis CNC tool grinding set CNC machining technology is mainly embodied in:

1. Precision High precision is the embodiment of tool quality, which is directly reflected in the production quality of machined parts. Due to the high precision requirements of modern CNC tools, the corresponding five-axis CNC tool grinding has the precision of precision machine tools. The machining accuracy of the foreign five-axis CNC tool grinding reaches 2μ, so the machine structure is optimized and designed with high-grade functional components, which have good static, dynamic and thermal performance.

2. The high-speed CNC tool processing form is mainly high-speed, high-precision shape grinding. The application of super-hard material grinding tools such as diamond grinding tools and CBN grinding tools puts new demands on the high-speed performance of the grinding machine. For example, the grinding wheel shaft generally adopts an electric spindle, and the rotating speed exceeds 10000r/ Min; requires the machine to have excellent electromechanical coupling, servo optimization and high acceleration performance. The application of direct drive components such as electric spindles, torque motors and linear motors has become a new highlight of high-speed performance of foreign high-end five-axis CNC tool grinding.

3. Composite multi-axis linkage control and multi-process composite grinding are one of the main technical features of five-axis CNC tool grinding. The five-axis CNC tool grinding can realize the complete grinding of complex profiles and composite tools in one loading. Because superhard materials such as polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PNCB) are used in CNC tools, it is not enough to grind such CNC tools with diamond wheels. Under the impetus of scientific and technological advancement, the technology of applying electric spark grinding and laser machining of numerical control tools has emerged as the times require. At present, 5-axis CNC tool grinding is used for rotating EDM of polycrystalline diamond. The integrated grinding wheel is ground on the same tool grinder. It can be used for twin-spindle and single-spindle models with electrode and grinding wheel replacement. It is mainly used for metal and wood. The processing of polycrystalline diamond tools in the processing industries such as ceramics and plastics has shown that composite machine tools using EDM and grinding wheel grinding of two-in-one composite processing PCD tools have also matured. Special processing and compound processing have become an important development direction of CNC tool grinding.

4. Intelligent five-axis CNC tool grinding is one of the most concentrated models of intelligent technology applications. The foreign advanced five-axis CNC tool grinding equipment is equipped with laser probe, grinding wheel probe, sonar sensor, CCD camera, etc. Its models generally have machine state monitoring and optimization, automatic compensation of dynamic and thermal states, anti-collision function, tool processing. In the machine inspection, the grinding wheel automatically repairs the calibration and dynamic balance functions on the line, which improves the intelligent level of tool grinding.

5. Application software "Half is hardware, half is software" This is the basic feature of five-axis CNC tool grinding CNC tools. Without the support of a large number of CNC tool grinding software, it is impossible to process a variety of CNC tool products with various forms and forms. General grinding software includes machining standard tool modules and non-standard tool modules. The operator can apply the database or set the tool geometry parameters to form a 3D graphics simulation machining program. For the grinding of complex-shaped tools such as tapered ball end mills, foreign companies with strong strength can precisely process them, because the machining of such tools requires high-precision multi-axis linkage CNC tool grinding machines and high-precision machining data calculation. Advanced grinding software. It can be seen that the five-axis CNC tool grinding is one of the most complete CNC machine tools for software development and application.

6. Automated robots are widely used in CNC tool grinding machines, which successfully solve the problems of automatic exchange of grinding wheels and automatic loading and unloading of workpieces, thus greatly improving the processing efficiency, accuracy and consistency of CNC tool grinding machines. The organic fusion of industrial robots and CNC tool grinding forms an automated grinding center (FMC).

In summary, the modern five-axis CNC tool grinding combines advanced manufacturing technology into one, becoming the carrier of contemporary high-tech integrated application. In addition, the five-axis CNC tool grinding can also be used for precision machining of special parts such as medical parts, IT and aerospace. It is foreseeable that the five-axis CNC tool grinding, which is hailed as the "elf", will play an increasingly important role in modern manufacturing.

three. Five-axis CNC tool grinding structure

The five-axis CNC tool grinding machine mainly grinds complex CNC tools. In order to achieve the grinding of complex curved surfaces, X, Y, Z, A or (B), C-- five-axis linkage is required for machine tool processing. The machine tool generally consists of a main moving part (grinding wheel), a feed moving part, an auxiliary part, a column, a stand, and the like. The layout structure of the five-axis CNC tool grinding moving parts is various, and it is divided into two types according to the main axis of the workpiece. Several types of machine tool structures commonly used at home and abroad are introduced.

1. Vertical alignment of the workpiece axis

As shown in Figure 6, the machine tool's main axis of the workpiece is vertically arranged to achieve 5-axis linkage:

X---Workpiece table lateral movement Y----Workpiece table longitudinal movement Z----The grinding head axis moves vertically up and down A---Workpiece spindle rotation angle 360 ​​degrees B--- Grinding head shaft rotation C- ---Workpiece table horizontal swing

Based on this layout, the grinding wheel can be approached to the workpiece at any angle from the front, the back, the left and the right, achieving 5-axis linkage, and the workpiece can be fully ground in one setup. This grinding method is flexible and efficient, eliminates the influence of the center of gravity of the workpiece, and has high machining accuracy.

2. The horizontal axis of the workpiece is laid out, and the workpiece table is rotated by A and C axes.

As shown in Fig. 7, the workpiece axis is horizontally laid, the workpiece table has an X axis, and the A and C axes are rotated; the grinding wheel spindle moves up and down and left and right to realize the Y and Z axis movement. The column can adopt the integral gantry type, the beam slides up and down in the column, and the grinding wheel shaft slides on the left and right sides of the beam. The combined structure is compact and the rigidity is excellent, the wheel axis moves smoothly, the workpiece is in the same horizontal plane, and the operation is convenient.

3. The horizontal axis of the workpiece is laid, the A-axis of the workpiece table rotates, and the B-axis of the grinding wheel spindle rotates.

As shown in Fig. 8, the workpiece axis is horizontally arranged, the workpiece table has X-axis, Z-axis and A-axis, and the grinding wheel spindle has Y-axis and B-axis. This combination is flexible, compact and efficient. .

4. The horizontal axis of the workpiece is laid, and the grinding wheel spindle realizes the C axis rotation.

As shown in Figure 9, the workpiece axis is horizontally laid, the workpiece table has X, Y, Z, A axes, and the grinding wheel spindle has a C axis. This combination increases the C-axis stiffness and the running stability of the grinding wheel. The grinding wheel movement accuracy is very favorable for the grinding wheel replacement; the workpiece table has more movement coordinates and a compact structure.

Fourth, key technologies and important supporting parts

1. Key Technologies High-end five-axis linkage CNC tool grinding involves the following key technologies:
(1) Finite element analysis and machine optimization design techniques for high-rigidity bed, column and main structural parts of precision machine tools for precision grinding;
(2) High-speed electric spindle (grinding head) structure optimization and lubrication and cooling technology;
(3) Virtual online dynamic balancing, detection and finishing technology for high-speed electric spindle grinding wheel;
(4) Rotary shaft-A/B/C structural design and high-precision motion technology;
(5) Linear axis-X/Y/Z design and repeated positioning accuracy control technology;
(6) Five-axis linkage tool processing program preparation and system software application technology;
(7) Automatic tool measurement and positioning system technology;
(8) Injection of high-speed grinding coolant and filtration and cooling technology of high-pressure and high-flow cutting fluid;
(9) Final assembly and commissioning technology of five-axis linkage CNC tool grinding machine.
(10) Automation technology such as industrial robot application

2. Important matching parts (1) CNC system High-performance five-axis CNC tool grinding requires CNC system with the following features: open architecture; high-precision nano-interpolation and motion control; networked digital system architecture; high-efficiency surface Machining performance; easy to NC programming and debugging. The CNC system should have multi-axis and multi-channel control; it has high-speed, high-precision motion performance; digital bus communication; intelligent functions such as dynamic compensation and servo optimization.

At present, foreign manufacturers generally use the FANUC31i system and the SIEMENS-840D SL system. This type of control system is highly versatile. Now tool grinder manufacturers are keen to develop special CNC systems and tool grinding software, such as ANCA's ANCA system, WALTER's HMC500 and HMC1500/200 systems, and Agton's AGATHON system. This trend indicates that the dedicated system can be used for the complexity and processing of random bed requirements, and the modular components are used to increase or decrease the processing function to achieve its versatility and economy. The CNC programming technology of the tool grinder special system combines various mathematical equation expressions, thus enabling a wide range of interpolation: linear interpolation, circular interpolation, involute interpolation, exponential function interpolation, and spiral interpolation. Complementary, spline function interpolation and other functions can solve high-precision machining of various complex shape tools.

The high-end CNC system developed by China Huazhong CNC Co., Ltd., Dalian Guangyang Technology Engineering Co., Ltd. and Guangzhou CNC Equipment Co., Ltd. has also been used for domestic five-axis CNC tool grinding.

(2) CNC tool grinding software Tool grinding software for foreign CNC tool grinding machine configuration can be divided into two categories: one is software developed by professional tool grinding software company, such as tool grinding software developed by Swiss MTS company Tool-kit PRO—FESSIONAL, tool grinding software NUMROTOplus developed by NUM in Switzerland, etc.; the other is software developed by the tool grinder manufacturer. This kind of grinding software includes not only the tool grinder manufacturer (known abroad). The tool grinding machine manufacturer is usually also a well-known tool manufacturer with knowledge of tool grinding and machine tool manufacturing, and incorporates its long-standing experience in tool production. Although the tool grinding software introduced by various companies differs in functions, intelligence, visualization, etc., they generally have 3D simulation, graphic guidance, parameterized programming functions, open tool grinding expert library, etc., in order to realize numerical control. Tool design and manufacturing.

China Huazhong CNC Co., Ltd. and Dalian Guangyang Technology Engineering Co., Ltd. have also developed CNC tool grinding software with independent intellectual property rights.

(3) The main functional components of the functional components include high-performance electric spindles (grinding head spindles), high-precision ball screws and linear rolling guides, high-precision linear and circular gratings, linear and torque motors, high-precision rolling bearings, high-precision CNC Turntable, precision hydrostatic bearing, hydrostatic guide rail, etc.

(4) Other matching parts The cutting fluid system of the machine tool needs to be equipped with high-pressure and large-flow filtering and cooling station. The machine tool requires the installation of oil mist eliminator, explosion-proof fire extinguishing and other environmental safety devices.

The intelligent and automatic functions of the machine tool need to configure the workpiece (tool) and automatic wheel measurement and positioning system, the grinding wheel virtual online dynamic balance detection device, as well as the grinding wheel library or automatic grinding wheel converter and robot, loading and unloading robot, etc., in order to improve the machine tool intelligence. The level of automation and automation meets the growing demand for high-efficiency and high-precision grinding of CNC tools.

V. Introduction to typical foreign products

1.WALTER Helitronic Power type tool grinding is shown in Figure 10. The machine is horizontally laid out on the axis of the workpiece, the gantry type column structure, the workpiece table with the X axis, and the A and C axis rotation; the grinding wheel spindle up and down Move realizes the Y and Z axes. One-time loading can realize the grinding of complex CNC tools with Ф3-320mm and length of 350mm. The machine is equipped with FANUC31i CNC system, and the company develops its own CNC tool grinding software. The machine can be equipped with electric spindle grinding wheel, torque motor turntable, automatic tool positioning probe, automatic wheel changing device, tool online contour measuring instrument, automatic tool support frame, automatic tool loading and unloading device. Options include: feedrate optimizer, tool balancer, integrated measurement system, torque adaptive control, and more.

2. Australian ANCA company MX5 five-axis CNC tool grinding

The model is horizontally arranged by the axis of the workpiece, and the gantry-type column structure adopts ANCA CNC CONTROL control system to realize X, Y, Z, A, C-five-axis linkage. X/Y/Z---540/510/215mm, C/A---264°/360°, main power 14kW; machine tool has 2 sets of grinding wheel frame system, grinding wheel shaft speed 10000r/min, its exchange time is 10s The grinding wheel has a maximum diameter of 203mm; it is equipped with a laser continuous measuring system and has a robot loading and unloading system. The workpiece has a diameter of 100mm and a processing length of 300mm. It has self-developed 3D simulation grinding software.

Sixth, accelerate the development of domestic high-end five-axis CNC tool grinding recommendations

Overall, compared with the advanced level in foreign countries, the domestic five-axis CNC tool grinding has gaps in machining accuracy, efficiency, intelligence, automation, CNC and software technology, reliability and amenity, and accelerates the development of domestic high-end five-axis CNC. Tool grinding requires national industrial policy and science and technology policy support, and it requires industry efforts. To this end, the following recommendations are made:

(1) Increase the support of the national science and technology major special project of “high-grade CNC machine tools and basic manufacturing equipment” for the research, development, demonstration and promotion of five-axis CNC tool grinding.

(2) Focus on improving the technical level, product quality and reliability of the domestic five-axis tool grinding. For the production enterprises, it is recommended to implement the preferential policies of VAT first-class return and return according to the sales of five-axis tool grinding, and encourage the promotion and application.

(3) Vigorously develop the functional components required for the five-axis CNC tool grinding products, and provide supporting support for the industrial chain for product upgrade and industrialization.

(4) Support key key enterprises to implement technological transformation and improve the manufacturing process equipment level and test detection capability of five-axis CNC tool grinding.

(5) Encourage the leading enterprises as the leading factor, take the market demand as the traction, combine the “production, study and research”, especially strengthen the cooperation between the leading enterprises of tool manufacturing and tool grinding machine manufacturing, and promote the industrialization of scientific and technological achievements.

Seven, the conclusion

"If you want to do something good, you must first sharpen your tools." Promoting the domestic five-axis CNC tool grinding to improve the technical level and industrialization, accelerate the development of domestic high-end five-axis CNC tool grinding, to meet the needs of China's manufacturing industry, has become an urgent task for the transformation and upgrading of the machine tool industry. We appeal to powerful enterprises and people with lofty ideals to contribute to the development of domestic high-end five-axis CNC tool grinding.

Specifications

Here are all METABO power tools and the designated carbon brushes,motor brushes, electric brushes, motor brushes, electric motor brushes or simply brushes.

For each power tool, there are usually two carbon brushes to choose from: With automatic stop and without automatic stop. Carbon brushes with automatic stop have a spring through the length of the carbon brush. When the carbon brush wears out, the spring gets released, the current to the carbon brush gets interrupted and your power tools switches off at once. The advantage: No additional wear and tear to your power tool. Carbon brushes without automatic stop do not stop functioning at once, but performance of your power tool will detoriate rapidly. Although handy as a warning sign, this usually isn't very beneficial to your power tool.

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